| Process Code | Description | Process Characteristic | Product Characteristic | Source of Variation |
|---|---|---|---|---|
| 1 | Receipt of Material | Order Qty & Verification W.R.T Invoice |
- | - |
| 2 | Raw Material Inspection | - | Chemical, Physical & Metallurgical | Material Mix-up, Surface Defects, Dimension |
| 3 | Storage | Specific Storage Area | Colour Code | Material Mix-up |
| 4 | Cutting | Cutting Feed, Blade Life | Cut Blank Weight, Taper | Material Mix-up |
| 5 | Heating | Temperature, Soaking Time | - | Weight Variation, Mix-up |
| 6 | Forging | Die Temperature, Cut Blank Temp. | Dimensions, Diameter, Length | Scale Pit, Mix-up |
| 7 | Trimming & Piercing | - | Trim & Pierce Dimension | Lap, Dent Mark, Mismatch |
| 8 | Normalised | Temperature, Soaking Time | Hardness | Mismatch, Flash, Dent Mark |
| 9 | Lab Inspection | - | Hardness, Microstructure | Hardness Variation, Bad Microstructure |
| 10 | Shot Blasting | Grit Size, Cycle Time | Surface Condition | Overheating, Scale Pit, Flash |
| 11 | Flash Grinding | Surface Speed | Burr Projection | Sticky Scale |
| 12 | Coining | Temperature | Dimension, Straightness | Stress |
| 13 | Final Inspection | - | Visual & Dimensional Check | Mismatch, Crack, Excess Grinding |